Curved Zippers

ABSTRACT

A zipper with at least one curve includes a first tape and a second tape, and interlocking elements attached to the first tape and the second tape, wherein the first tape and the second tape are curved, and wherein a curve of at least one of the tapes was caused by compaction of that tape.

RELATED APPLICATIONS

This application is a continuation of PCT/IB2020/061005, filed Nov. 23,2020, published as WO/2021/100021, which claims the benefit of U.S.provisional patent application No. 62/939,590, filed Nov. 23, 2019, theentire contents of both of which are hereby fully incorporated herein byreference for all purposes.

COPYRIGHT STATEMENT

A portion of the disclosure of this patent document contains materialwhich is subject to copyright protection. The copyright owner has noobjection to the facsimile reproduction by anyone of the patent documentor the patent disclosure, as it appears in the Patent and TrademarkOffice patent file or records, but otherwise reserves all copyrightrights whatsoever.

FIELD

This invention relates generally to zippers and, more particularly, insome aspects, to curved zippers and to zippers that stretch and recover.

BACKGROUND

Zippers are ubiquitous and have long been used to fasten or otherwisesecure items such as jackets, luggage, pockets, and other types ofproducts. A typical zipper may include a slider configured with twoface-to-face rows of elements or teeth or interlocking spirals. The rowsof elements are typically connected to a tape or the like, and, as theslider is moved along the tape in one direction, the two rows of teethmay pass through the slider, and the teeth may be interlocked, resultingin a combined zipper chain. As the slider is moved along the tape in theopposite direction, the rows of teeth separate. In this way, as is wellknown, an item configured with the zipper may be fastened or unfastened.

Conventionally, the tapes are made of a fabric or substrate such ascotton or polyester or nylon. The interlocking elements (e.g., teeth ora coil) may be made up of many things, including brass, steel, stainlesssteel, nylon, or poly.

The inventor has realized that conventional zippers have variousproblems, including:

-   -   (1) The tapes may shrink, making an attached item (e.g., a        garment) look unsightly. Sometimes the tapes may not shrink in        the same amount as the garment fabric to which it is attached,        making the garment look unsightly.    -   (2) Zippers do not stretch.    -   (3) Zippers do not stretch and recover.    -   (4) Zippers generally cannot curve, so they are attached to        items (e.g., garments or bags or the like) “standing up”—in a        straight line.

Curved zippers are known in principle from the art.

Some approaches use cuts and notches in the carrier tapes in the regionof the desired bend. Examples of these are shown in FIGS. 1A-1F (seeFIG. 2a of US20130205548A1 in FIG. 1A; FIG. 4 of WO2006000086A2 in FIG.1B; FIG. 6 of WO2017117285A1 in FIG. 1C; FIGS. 1 and 2 of DE7122407 inFIGS. 1D-1E; and FIG. 1 of CN201782133U in FIG. 1F).

The “cuts and notches” approach has various drawbacks, including thatthe cuts and notches create weak locations in the carrier tapes.

Another known approach to curved zippers, shown in U.S. Pat. No.8,011,070, attaches “stretchable members” to the zipper tapes in variouslocations “as a reinforcement member for the fastener tape to maintainits curved shape”. U.S. Pat. No. 8,011,070 col. 7, lines 57-58 (see alsoFIG. 2 of U.S. Pat. No. 8,011,070 reproduced in part in FIG. 1G hereof).As described in U.S. Pat. No. 8,011,070, the so-called stretchablemember has to be held (sewn) in place in its deformed (curved) state;otherwise it will be restored to its original state. In anotherconfiguration in U.S. Pat. No. 8,011,070, “the stretchable member . . .may be formed by coating the tape surface . . . of the fastener tape . .. with a rubber made belt material . . . continuously in the lengthdirection of the fastener tape . . . in a belt-like formation . . . .The belt material . . . is applied to the fastener tape . . . by coatingin a state in which the rubber is heated to be softened, so that therubber invades in between fibers of the fastener tape . . . and fixedintegrally with the fastener tape . . . . Thus, no adhesive layer isneeded to fix the belt material . . . to the fastener tape.” U.S. Pat.No. 8,011,070, col. 8, lines 55-64.

A method of producing a curved zipper is known from U.S. Pat. No.5,065,491A, in which a carrier tape of solvent-swelling fibers isproduced so that the fibers swell when a solvent is applied to thecarrier tape, and the tape (and zipper) is shaped into the desiredcurved configuration. The shape is not retained permanently. The methodis not suitable for production by machine, and it is expensive.

Accordingly, it is desirable and an object hereof to provide a curvedzipper that maintains its curve, even when not connected to a garment orother device.

It is also desirable and an object hereof to provide a curved zipperthat does not have weak attachment points and thus maintains itsstrength and integrity along its length.

It is further desirable and an object hereof to provide a zipper thatdoes not have excessive shrinkage.

It is further desirable and an object hereof to provide a zipper withuniform shrinkage.

It is further desirable and an object hereof to provide a zipper withstretch properties.

It is further desirable and an object hereof to provide a zipper withstretch and recovery properties.

SUMMARY

The present invention is specified in the claims and the belowdescription. The following summary is exemplary and not limiting.Presently preferred embodiments are particularly specified in thedependent claims and the description of various embodiments.

Zippers That Deal with too Much Shrinkage

One general aspect includes a zipper with two tapes, where at least oneof the two tapes is formed from a compacted fabric. The zipper alsoincludes multiple interlocking elements (e.g., teeth) connected to eachof the two tapes, where interlocking elements from each tape of the twotapes may join with interlocking elements of the other of the two tapes.

Implementations may include one or more of the following features, aloneor in combination(s):

-   -   the zipper where the fabric is selected from cotton or polyester        or nylon; and/or    -   the zipper where the tapes were compacted before being connected        to the interlocking elements; and/or    -   the zipper where the interlocking elements may include teeth or        a coil; and/or    -   the zipper where the interlocking elements are formed from brass        or steel or stainless steel or nylon; and/or    -   the zipper where the two tapes have different degrees of        compaction.

Zippers That Deal with too Little Shrinkage

Another general aspect includes a garment may include a garment fabricand a zipper attached to one or more portions of the garment fabric.

Implementations may include one or more of the following features, aloneor in combination(s):

-   -   the garment where the garment fabric is preshrunk by compaction;        and/or    -   the garment where the zipper may include two zipper tapes, and        where the zipper tapes have a first shrinkage and where the        garment fabric has a second shrinkage larger than the first        shrinkage; and/or    -   the garment where the zipper may include two zipper tapes, and        where the zipper tapes have a first and second shrinkage and        where the garment fabric has a third shrinkage larger than the        first and second shrinkages; and/or    -   the garment where the garment fabric was preshrunk such that the        shrinkage of the preshrunk garment fabric is substantially equal        to the shrinkage of the zipper tapes.

Another general aspect includes a method of making a garment. The methodof making also includes providing a zipper having two zipper tapes,where the zipper tapes have a first shrinkage, and providing a garmentfabric where the garment fabric has a second shrinkage larger than thefirst shrinkage. The method also includes compacting the garment fabricto produce a compacted garment fabric, where the compacted garmentfabric has a third shrinkage, where the third shrinkage is substantiallyequal to the first shrinkage. The method also includes connecting thezipper tapes to the compacted garment fabric.

Implementations may include washing the garment.

Zippers That Stretch

Another general aspect includes a zipper having two tapes, each formedfrom a compacted fabric. The zipper also includes multiple interlockingelements (e.g., teeth) attached to the two tapes after the fabric wascompacted, where interlocking elements from each tape may join withinterlocking elements of the other tape.

Implementations may include one or more of the following features, aloneor in combination(s):

-   -   where the compacted fabric was compacted to remove all or        substantially all shrinkage of the fabric; and/or    -   where the tapes have different degrees of compaction.

Another general aspect includes a method of making a zipper, includingcompacting two tapes to form two compacted tapes; and then attachinginterlocking elements to the two tapes.

Implementations may include one or more of the following features, aloneor in combination(s):

-   -   where the two tapes are compacted to remove substantially all of        their shrinkage; and/or    -   where the tapes have different degrees of compaction.

Another general aspect includes a method of making a zipper, includingattaching interlocking elements to two tapes; and then compacting thetwo tapes.

Implementations may include one or more of the following features, aloneor in combination(s):

-   -   the method where compaction of the two tapes uses a compactor;        and/or    -   the method where the compactor includes at least one drum;        and/or    -   the method where the drum has a notch or groove to allow the        zipper's interlocking elements to pass without pressure from the        drum while the tapes on either side of the interlocking elements        are being compacted; and/or    -   where the tapes have different degrees of compaction; and/or    -   the method where the drum is heated.

Another general aspect includes a drum for a compactor, where the drumhas a notch or groove to allow a zipper's interlocking elements to passwithout pressure from the drum while tapes on either side of thezipper's interlocking elements are being compacted by the drum.

Zippers That Stretch and Recover

Another general aspect includes a zipper including two tapes, eachformed from a compacted fabric, where at least one of the two tapes hasa fusible substrate fused with the compacted fabric. The zipper alsoincludes multiple interlocking elements connected to each of the twotapes, where interlocking elements from each tape may join withinterlocking elements of the other tape.

Implementations may include one or more of the following features, aloneor in combination(s):

-   -   the zipper where both of the tapes include the fusible substrate        fused with the compacted fabric; and/or    -   the zipper where at least one of the two tapes may include the        fusible substrate fused with the compacted fabric along        substantially a length of the tapes; and/or    -   the zipper where interlocking elements were attached to the two        tapes after the fabric was compacted; and/or    -   the zipper where interlocking elements were attached to the two        tapes after the fusible substrate was fused with the compacted        fabric; and/or    -   where the tapes have different degrees of compaction.

Another general aspect includes a method of making a zipper. The methodincludes compacting a tape to form a compacted tape and fusing a fusiblesubstrate to the compacted tape. The method also includes attachinginterlocking elements to the compacted tape.

Implementations may include one or more of the following features, aloneor in combination(s):

-   -   the method may include compacting a second tape to form a second        compacted tape; fusing the fusible substrate to the second        compacted tape; and attaching the interlocking elements to the        second compacted tape; and/or    -   the method where the tape is compacted using a heated drum;        and/or    -   where the tapes have different degrees of compaction.

Another general aspect includes a method of making a zipper, includingattaching a first tape to a first side of a zipper chain and attaching asecond tape to a second side of the zipper chain; and then compactingthe first tape and the second tape; and then fusing a fusible substratewith the first tape.

Implementations may include fusing the fusible substrate with the secondtape.

Zippers That Curve

Another general aspect includes a zipper having a first tape and asecond tape and interlocking elements attached to the first tape and thesecond tape, where the first tape and the second tape are curved, andwherein a curve of the first tape was caused by compaction of the firsttape.

Implementations may include one or more of the following features, aloneor in combination(s):

-   -   the zipper where a curve of the second tape was caused by        compaction of the second tape; and/or    -   the zipper where the second tape is woven with a second edge        portion having a tighter weave than the rest of the second tape;        and/or    -   the zipper where the first tape was compacted using a compactor;        and/or    -   the zipper where the first tape is woven with a first edge        portion having a tighter weave than the rest of the first tape;        and/or    -   the zipper where interlocking elements were attached to the        first tape after the first tape was curved; and/or    -   the zipper where interlocking elements were attached to the        second tape after the second tape was curved; and/or    -   the zipper where interlocking elements were attached to the        first tape before the first tape was curved; and/or    -   the zipper where interlocking elements were attached to the        second tape before the second tape was curved; and/or    -   the zipper where at least a portion of the first tape has        stretch; and/or    -   the zipper where at least a portion of the first tape has        stretch and recovery properties; and/or    -   the zipper where at least a portion of the first tape is fused        with a fusible substrate; and/or    -   the zipper where the first and second tapes have different        degrees of curvature;    -   the zipper where less than the entire zipper is curved; and/or    -   the zipper where the zipper has more than one curve.

Another general aspect includes a method of making a zipper, includingproviding a first tape, the first tape woven with a first edge portionhaving a tighter weave than the rest of the first tape. The making alsoincludes compacting a first tape to form a curved first tape. The makingalso includes attaching interlocking elements to the curved first tape.

Implementations may include one or more of the following features, aloneor in combination(s):

-   -   the method may include attaching a curved second tape to the        interlocking elements; and/or    -   the method where the curved second tape was formed by        compaction; and/or    -   the method where the first and second tapes have different        degrees of curvature; and/or    -   the method may include after the compacting, fusing a fusible        substrate to the first tape.

Yet another general aspect includes a product including a zipperassembly according to any of the previous embodiments. The product maybe, e.g., a garment, clothing, footwear (shoes, boots, etc.), an item ofluggage, or a sports item. Non-limiting examples of products include,without limitation, bags, pencil cases, backpacks, computer/laptopcases, luggage, zip-up portfolio case, zip-up storage bins for toys,sleeping bags, tents, boat covers, children make up/toiletry bags, lunchbags, hats with zipper pockets, toys, toy clothing, etc.

Below is an exemplary list of zipper embodiments, method/processembodiments, and garment embodiments. The zipper embodiments will beindicated with a letter “Z”. Whenever such embodiments are referred to,this will be done by referring to “Z” embodiments. The garmentembodiments will be indicated with a letter “G”. Whenever suchembodiments are referred to, this will be done by referring to “G”embodiments. The method embodiments will be indicated with a letter “M”.Whenever such embodiments are referred to, this will be done byreferring to “M” embodiments. Drum embodiments will be indicated with aletter “DR”. Whenever such embodiments are referred to, this will bedone by referring to “DR” embodiments.

-   -   Z1. A zipper comprising:        -   two tapes; and        -   multiple interlocking elements connected to each of the two            tapes,        -   wherein interlocking elements from each tape of the two            tapes may join with interlocking elements of the other of            the two tapes, and        -   wherein at least one of the two tapes is formed from a            compacted fabric.    -   Z2. The zipper of embodiment Z1, wherein the fabric is selected        from cotton or polyester or nylon.    -   Z3. The zipper of embodiment(s) Z1 or Z2, wherein the tapes were        compacted after being connected to the interlocking elements.    -   Z3′. The zipper of embodiment(s) Z1 or Z2, wherein the tapes        were compacted prior to being connected to the interlocking        elements.    -   Z4. The zipper of embodiment(s) Z1-Z3′, wherein the tapes have        different degrees of compaction.    -   Z5. The zipper of any of embodiment(s) Z1-Z4, wherein the        interlocking elements comprise teeth or a coil.    -   Z6. The zipper of any of embodiment(s) Z1-Z5, wherein the        interlocking elements are formed from brass or steel or        stainless steel or nylon.    -   G7. A garment comprising a garment fabric and a zipper attached        to one or more portions of the garment fabric, wherein at least        some of the garment fabric is preshrunk before attachment to the        zipper.    -   G8. The garment of embodiment(s) G7, wherein the garment fabric        is preshrunk by compaction.    -   G9. The garment of embodiment(s) G7 or G8, wherein the zipper        comprises two zipper tapes, and wherein the zipper tapes have a        first shrinkage and wherein the garment fabric has a second        shrinkage larger than said first shrinkage.    -   G10. The garment of any of embodiment(s) G76-G9, wherein the        garment fabric was preshrunk such that the shrinkage of the        preshrunk garment fabric is substantially equal to the shrinkage        of the zipper tapes.    -   M11. A method of making a garment, the method comprising:        -   providing a zipper having two zipper tapes, wherein the            zipper tapes have a first shrinkage;        -   providing a garment fabric wherein the garment fabric has a            second shrinkage larger than said first shrinkage;        -   compacting the garment fabric to produce a compacted garment            fabric, wherein the compacted garment fabric has a third            shrinkage, wherein said third shrinkage is substantially            equal to the first shrinkage; and        -   connecting the zipper tapes to the compacted garment fabric.    -   M12. The method of embodiment(s) M11 further comprising washing        the garment.    -   Z13. A zipper comprising:        -   two tapes, each formed from a compacted fabric; and        -   multiple interlocking elements connected to each of the two            tapes,        -   wherein interlocking elements from each tape may join with            interlocking elements of the other tape, and        -   wherein interlocking elements were attached to the two tapes            after the fabric was compacted.    -   Z13′. A zipper comprising:        -   two tapes, each formed from a compacted fabric; and        -   multiple interlocking elements connected to each of the two            tapes,        -   wherein interlocking elements from each tape may join with            interlocking elements of the other tape, and        -   wherein interlocking elements were attached to the two tapes            before the fabric was compacted.    -   Z14. A zipper according to embodiment(s) Z13 or Z13′, wherein        the compacted fabric was compacted to remove all or        substantially all shrinkage of the fabric.    -   M15. A method of making a zipper, the method comprising:        -   compacting two tapes to form two compacted tapes; and        -   attaching interlocking elements to the two tapes.    -   M16. A method of making a zipper, the method comprising:        -   attaching interlocking elements to two tapes; and then        -   compacting the two tapes.    -   M17. The method of embodiment(s) M15 or M16, wherein the two        tapes are compacted to remove substantially all of their        shrinkage.    -   M18. The method of any of embodiment(s) M15-M17, wherein        compaction of the two tapes uses a compactor.    -   M19. The method of any of embodiment(s) M15-M18, wherein the two        tapes have different degrees of compaction.    -   M20. The method of embodiment(s) M19, wherein the compactor        includes at least one drum.    -   M21. The method of embodiment(s) M20, wherein the at least one        drum has a notch or groove to allow a zipper's interlocking        elements to pass without pressure from the at least one drum        while the tapes on either side of the interlocking elements are        being compacted by the at least one drum.    -   M22. The method of embodiment(s) M20-M21, wherein the at least        one drum is heated.    -   DR23. A drum for a compactor, the at least one drum comprising a        notch or groove to allow a zipper's interlocking elements to        pass without pressure from the at least one drum while tapes on        either side of the zipper's interlocking elements and attached        to the zipper are being compacted by the at least one drum.    -   Z24. A zipper comprising:        -   two tapes, each formed from a compacted fabric, wherein at            least one of the two tapes comprises a fusible substrate            fused with the compacted fabric; and        -   multiple interlocking elements connected to each of the two            tapes, wherein interlocking elements from each tape may join            with interlocking elements of the other tape.    -   Z25. The zipper of embodiment(s) Z24, wherein the two tapes have        different degrees of compaction.    -   Z26. The zipper of embodiment(s) Z24-Z25, wherein both of the        two tapes comprise said fusible substrate fused with the        compacted fabric.    -   Z27. The zipper of embodiment(s) Z24-Z26, wherein at least one        of the two tapes comprises said fusible substrate fused with the        compacted fabric along substantially a length of the tapes.    -   Z28. The zipper of any of embodiment(s) Z24-Z27, wherein the        interlocking elements were attached to the two tapes after the        fabric was compacted.    -   Z29. The zipper of any of embodiment(s) Z24-Z28, wherein the        interlocking elements were attached to the two tapes after the        fusible substrate was fused with the compacted fabric.    -   M30. A method of making a zipper, the method comprising:        -   compacting a tape to form a compacted tape;        -   fusing a fusible substrate to the compacted tape; and        -   attaching interlocking elements to the compacted tape.    -   M31. The method of embodiment(s) M30, further comprising:        -   compacting a second tape to form a second compacted tape;        -   fusing said fusible substrate to the second compacted tape;            and        -   attaching interlocking elements to the second compacted            tape.    -   M32. The method of embodiment(s) M30 or M31, wherein the tape is        compacted using a heated drum.    -   M33. A method of making a zipper, the method comprising:        -   attaching interlocking elements to a first tape and to a            second tape; and then        -   compacting the first tape and the second tape; and then        -   fusing a fusible substrate with the first tape.    -   M34. The method of embodiment(s) M33 further comprising:        -   fusing said fusible substrate with the second tape.    -   Z35. A zipper comprising:        -   a first tape and a second tape; and        -   interlocking elements attached to the first tape and the            second tape,        -   wherein the first tape and the second tape are curved, and        -   wherein a curve of the first tape was caused by compaction            of the first tape.    -   Z36. The zipper of embodiment(s) Z35, wherein the tapes have        different degrees of compaction.    -   Z37. The zipper of embodiment(s) Z35-Z36, wherein a curve of the        second tape was caused by compaction of the second tape.    -   Z38. The zipper of embodiment(s) Z35-Z37, wherein the first tape        was compacted using a heated press.    -   Z39. The zipper of any of embodiment(s) Z35-Z38, wherein the        first tape is woven with a first edge portion having a tighter        weave than the rest of the first tape.    -   Z40. The zipper of any of embodiment(s) Z35-Z39, wherein the        second tape is woven with a second edge portion having a tighter        weave than the rest of the second tape.    -   Z41. The zipper of any of embodiment(s) Z35-Z40, wherein the        interlocking elements were attached to the first tape before the        first tape was curved.    -   Z41′. The zipper of any of embodiment(s) Z35-Z40, wherein the        interlocking elements were attached to the first tape after the        first tape was curved.    -   Z42. The zipper of any of embodiment(s) Z35-Z41′, wherein the        interlocking elements were attached to the second tape before        the second tape was curved.    -   Z42′. The zipper of any of embodiment(s) Z35-Z41′, wherein the        interlocking elements were attached to the second tape after the        second tape was curved.    -   Z43. The zipper of any of embodiment(s) Z35-Z42′, wherein at        least a portion of the first tape has stretch.    -   Z44. The zipper of any of embodiment(s) Z35-Z43, wherein at        least a portion of the first tape has stretch and recovery        properties.    -   Z45. The zipper of any of embodiment(s) Z35-Z44, wherein at        least a portion of the first tape is fused with a fusible        substrate.    -   Z46. The zipper of any of embodiment(s) Z35-Z45, wherein less        than the entire zipper is curved.    -   Z47. The zipper of any of embodiment(s) Z35-Z46, wherein the        zipper has more than one curve.    -   Z48. The zipper of any of embodiment(s) Z35-Z47, wherein the        first tape has a different degree of curvature than the second        tape.    -   M49. A method of making a zipper, the method comprising:        -   providing a first tape, said first tape woven with a first            edge portion having a tighter weave than the rest of the            first tape;        -   compacting a first tape to form a curved first tape; and        -   attaching interlocking elements to the curved first tape.    -   M49′. A method of making a zipper, the method comprising:        -   providing a first tape, said first tape woven with a first            edge portion having a tighter weave than the rest of the            first tape;        -   attaching interlocking elements to the curved first tape;            and        -   compacting a first tape to form a curved first tape.    -   M50. The method of embodiment(s) M49-M49′, further comprising:        attaching a curved second tape to the interlocking elements.    -   M51. The method of embodiment(s) M49-M50, wherein the curved        second tape was formed by compaction.    -   M52. The method of any of embodiment(s) M49-M51, further        comprising after said compacting, fusing a fusible substrate to        the first tape.    -   M53. The method of any of embodiment(s) M49-M52, wherein the        first tape has a different degree of curvature than the second        tape.

Below are product embodiments indicated with the letter “P”.

-   -   P54. A product comprising a zipper according to any of the        previous zipper embodiments.    -   P55. The product of embodiment(s) P54, wherein the product is        selected from:        -   a garment, footwear, an item of luggage, an item of sports            equipment, boat covers, bags, pencil cases, backpacks,            computer/laptop cases, luggage, zip-up portfolio case,            zip-up storage bins for toys, sleeping bags, tents, children            make up/toiletry bags, lunch bags, hats with zipper pockets,            toys, toy clothing.

BRIEF DESCRIPTION OF THE DRAWINGS

Various other objects, features and attendant advantages of the presentinvention will become fully appreciated as the same becomes betterunderstood when considered in conjunction with the accompanyingdrawings, in which like reference characters designate the same orsimilar parts throughout the several views, and wherein:

FIGS. 1A-1G show prior approaches to curved zippers (FIGS. 1A-1G showparts of drawings from other patent documents, and, to avoid confusion,the original drawings have been cropped and edited to remove referencenumbers used in those patent documents);

FIG. 2 shows aspects of a zipper;

FIG. 3 shows aspects of making zippers according to exemplaryembodiments hereof;

FIGS. 4A-4B, 5A-5B, and 6A-6E show aspects of zippers and making zippersaccording to exemplary embodiments hereof; and

FIGS. 7A-7C are photographs of curved zippers according to exemplaryembodiments hereof.

DETAILED DESCRIPTION OF THE PRESENTLY PREFERRED EXEMPLARY EMBODIMENTS

Zippers according to exemplary embodiments hereof are described here.

The following detailed description is not intended to limit the currentinvention. Alternate embodiments and variations of the subject matterdescribed herein will be apparent to those skilled in the art.

Background

As shown in FIG. 2, and as is well known, a zipper 10 (also referred toas a zipper assembly) includes a zipper chain 12 comprising twoindividual rows interlock elements, e.g., teeth (left row of teeth 14attached to left tape 16 and right row of teeth 18 attached to righttape 20) that, when interlocked, may form the combined zipper chain 12.A slider 100 may be configured and positioned such that the left row ofteeth 14 pass into and through a left-side channel 102 in the slider'stop left shoulder 104, and the right row of teeth 18 pass into andthrough a right-side channel 106 of the slider's top right shoulder 108.

The left and right side channels 102, 106 may combine below piece 110within the body cavity of slider 100 (generally hidden from view anddepicted with dashed lines in FIG. 1) to form a mouth 112. In operation,and as is known, as the left row of teeth 14 and the right row of teeth18 pass through mouth 112, they may interlock to form zipper chain 12.

As is also well known, the slider 100 may be moved from one end of thezipper to the other. As the slider is moved in one direction, the rowsof teeth (the left row of teeth 14 and right row of teeth 18) maycontinue to be interlocked as they pass through slider 100 to form thelength of the combined zipper chain 12. As slider 100 is moved in theother direction, it may contact the joined zipper chain 12 at a junctionbetween the left row of teeth 14 and the right row of teeth 18 to forcethem apart, separate them from one another, and generally unlock the tworows of teeth 14, 18. This separation and unlocking may result in twoseparate and individual rows of teeth 14, 18. This allows zipper chain12 to be combined to fasten the left and right sides together andseparated to unfasten them. In this way, the zipper 10 may be used as afastener for jackets, pockets, luggage, and other products.

The interlocking elements may be connected directly to the left andright tapes (e.g., in the case where they are metal teeth or the like),or they may be attached to a separate chain which is then attached tothe left and right tapes.

Description Zippers That Deal with too Much Shrinkage

In order to deal with too much shrinkage, the tapes may be compacted,e.g., using heat and pressure to remove some or all of the shrinkage.

For example, as shown in FIG. 3, a spool of tape 30 may be fed into acompactor 32 to produce compacted tape 34 with some or substantially allof the shrinkage in the tape removed. The compactor 32 may include adrum or the like. Those of skill in the art will understand, uponreading this description, that the amount of compaction of the tape 30by the compactor 32 will depend on the type and/or cut of material usedfor the tape 30, and the temperature, speed, and pressure of thecompactor 32.

The compacted tape 34 may be spooled. A zipper may then be formed usingthe compacted tape 34.

Zippers That Deal with too Little Shrinkage

Consider the case where a zipper is attached to a fabric of an item(e.g., a garment) and where the fabric shrinks at a higher rate than thetapes. For example, the fabric may shrink about 15 percent, whereas thezipper's tapes only shrink, say 2-5%. In those cases, after washing, thegarment will pucker along the zipper garment connection.

To deal with this case, preshrink the garment fabric by an amount thatleaves little or no shrinkage, in any case no more than the shrinkage ofthe zipper tapes. The fabric may be preshrunk by compaction. The zippertapes are attached to the garment after the fabric has beenshrunk/compacted.

So, in the example above, the garment fabric is preshrunk by at least10-15%.

The garment fabric, when attached to the zipper, may appear puckered, asthe garment body may still be bigger. However, after washing the body ofthe garment, the connected fabric and zipper will have shrunk and willlay flat.

Zippers That Stretch

In order to allow zippers to stretch, the tapes may be compacted toremove all or substantially all of their shrinkage (e.g., as shownabove). Then the teeth may be applied to the compacted tapes. In thisway, the resulting zipper will be able to stretch the amount compacted.

In an alternate approach, the zipper may be formed with pre- orun-compacted tapes, and then the fully-formed zipper may be compacted.The resulting zipper will stretch by the amount compacted.

An exemplary approach to compacting the zippers is shown in FIG. 4A, inwhich assembled zippers 36 (with teeth attached to tapes) are fed into acompactor 38, e.g., on a belt 40 or the like. The compactor 38 mayinclude one or two drums 42, 44. Since the zipper 36 is already at leastpartially assembled, one or both of the drums 42, 44 are cut or groovedto allow the zipper's rail (teeth) to pass through uncompacted, whilethe tapes on either side of the rail are compacted.

As shown in FIG. 4B, zipper includes a left tape 50-L and a right tape50-R, connected to the rail or teeth elements 52. As noted, in order toprevent compaction of the teeth elements 52, the drum 42 may include anotch or groove or cut 54 to allow the teeth elements 52 to pass throughuncompressed. A similar notch or the like may be incorporated into thedrum 44, in which case the zippers 36 may be fed into the compactor 38with the teeth elements facing up or down.

One or both of the drums 42, 44 may be grooved and/or coated, at leastin the regions that will come into contact with the tapes.

The compactor 38 may include a suitable guide mechanism 46 to correctlyand accurately position the zippers 36 as the pass between the drums 42,44. The compacted zipper 48 may then be attached to an item (e.g., agarment or the like).

In order to achieve compaction of the zippers 36, one or both of thedrums may be heated. Those of skill in the art will understand, uponreading this description, that the amount of compaction of the tape bythe compactor 38 will depend on the type and/or cut of material used forthe tape, and the temperature, speed, and pressure of the compactor 38.The compressed zipper 48 will be able to stretch the amount compacted.

Zippers That Stretch and Recover

In order to allow zippers to stretch and recover, the tapes may becompacted to remove their shrinkage. Then a fusible (e.g., a 2-wayfusible substrate) may be applied to the back of the tapes to providememory to the tapes.

For example, as shown in FIG. 5A, a zipper 36 may be passed through acompactor 38, e.g., as described above, to remove shrinkage of thetapes. Then a fusible substrate (or fusible) 56 may be applied to theback of the tapes (50-L, 50-R) to provide a memory and allow it torecover after it is stretched. The zipper 36 and the fusible substrate56 are fed into a heating press 58, preferably using a guide 60. Theheating press 58 may include two rollers 62, 64. The result is a zipper66 in which the tapes have been compacted (by compactor 38) and then befused with a fusible substrate (by heating press 58).

The speed, temperature, and pressure of the heating press 58 depend onthe type of fabric used for the tapes and on the type of fusiblesubstrate 56 being used.

The speed, temperature, and pressure of the heating press 58 need not bethe same as those of the compactor 38, as the compactor 38 is used tocompact the tape fabric, whereas the heating press 58 is used to fusethe fusible substrate 56 to the compacted tape fabric.

As shown in FIG. 5B, the fusible substrate 56 is preferably in twoparts, namely fusible substrate 56-L for the left tape 50-L and fusiblesubstrate 56-R for the right tape 50-R.

The fusible substrate is preferably a 2-way stretchable fusible.

As an alternative, before the zipper is assembled, the tapes may becompacted (to remove shrinkage) and then fused with a fusible to providememory to the tapes (so that they may recover after being stretched).Then the teeth may be applied to the compacted tapes that have alreadybeen fused with a fusible substrate. In this way, the zipper will beable to stretch the amount compacted and recover an amount depending onthe fusible used.

Zippers That Curve

To make zippers that curve according to exemplary embodiments hereof,the zipper tapes are curved, and then the teeth elements are attached tothe tapes.

In some cases, e.g., as shown in FIG. 6A, the tape 70 is woven with aself-edge 72 (shaded in the drawing in FIG. 6A) that is tighter than therest of the tape 74.

The self-edge 72 has a width Ws, and the rest of the tape has a widthWr, where Ws+Wr is the width of the tape Wt. Those of skill in the artwill know and understand, upon reading this description, how to selectthe ratio of Ws to Wr (or of Ws to Wt) to achieve a desired curvaturefor the zipper.

The tape 70 is compacted using a heated compactor. When compacted, theself-edge 72 will compact less than the rest of tape 74. Thus, aftercompaction, the rest of the tape 74 will open up more than the self-edge72. This will cause the tape 70 to curve, e.g., as shown in FIG. 6B.

As shown, e.g., in FIG. 6C, the tapes 70-L, 70-R for the left and rightsides of a zipper should be curved so that the outside edge of one sidehas tighter compaction than the rest of that side, and, for the othertape side, the inside edge has tighter compaction than the rest of thetape.

The two curved tapes 70-L, 70-R may then be joined with their teeth, asshown in FIG. 6D, to form a curved zipper 76.

If the tapes 70-L, 70-R are compacted with a drum, the tapes may be doneon opposite sides of the drum before being joined with the teeth.

In some cases, the self-edge may have stretch, allowing the curve tostretch. For example, in some implementations, the self-edge of the tapefaces the outside of the drum to allow the curve to stretch. Fusible maybe added to the self-edge to allow it to stretch and recover.

FIGS. 6A-6D show only a portion of a curved tape or curved zipper. Asshould be understood, other parts of the zipper may be straight or mayalso be curved. Different parts of a zipper may have different degreesof curvature. A zipper may have multiple curves. In some cases, tapeswith different curvatures may be joined (e.g., sewn together) to form azipper with multiple curvatures. The two tapes may have been formed orcompacted separately. For example, a first zipper with a first curvaturemay be formed (as described above), and a second zipper with a secondcurvature may be formed (also as described above), and then a tape fromthe first zipper (having the first curvature) may be used with a tape ofthe second zipper (having the second curvature).

FIGS. 7A-7C are photographs of curved zippers according to exemplaryembodiments hereof. FIG. 7B shows aspects of a region 78 of the curvedzipper 76″ of FIG. 7A. In particular, FIG. 7B shows the regions 72″ and74″ on the zipper 76″ (corresponding to the regions 72 and 74 in FIG.6A).

EXAMPLES

FIGS. 7A-7B are photographs of curved zippers according to exemplaryembodiments hereof.

An example curved zipper, according to exemplary embodiments hereof, wastested against existing zippers. The results of these tests aresummarized in the following table:

Inside Strength Zipper Flexibility Pucker Reduction Curved zipper Up to7% reduced  5-10% according to exemplary embodiments hereof Zipper withknitted Up to 5% Same as 20-30% tapes regular zip Zipper withstretchable Up to 10% Higher than 30-50% tapes regular zip Zipper withcut tapes 50% Higher than 20-30% Lateral regular zip

Discussion

Thus are described various zippers, items using the zippers, and methodsof making the zippers and the items.

The above description includes description of zippers that deal with toomuch shrinkage; and/or zippers that deal with too little shrinkage;and/or zippers that stretch; and/or zippers that stretch and recover;and/or zippers that curve. Although exemplary embodiments are describedunder various headings (e.g., Zippers that deal with too much shrinkage,Zippers that deal with too little shrinkage, Zippers that Stretch,Zippers that Stretch and recover, and Zippers that Curve), theseheadings are to aid this description and are not intended to limit thescope of any of the embodiments. Those of ordinary skill in the art willrealize and appreciate, upon reading this description, that the variousembodiments under a given heading are not intended to be exclusive ormutually exclusive and that the various approaches may be combined. Forexample, a zipper that curves may also have stretch or stretch andrecovery properties, and zippers that deal with too little or too muchshrinkage may also curve and also stretch and recover.

In addition, when a particular property (e.g., stretch and recovery) isapplied to one tape of a zipper assembly, that same approach need notapply to the other tape of the zipper assembly.

Conclusion

As used herein, including in the claims, the phrase “at least some”means “one or more” and includes the case of only one. Thus, e.g., thephrase “at least some ABCs” means “one or more ABCs” and includes thecase of only one ABC.

As used in this description, the term “portion” means some or all. So,for example, “A portion of X” may include some of “X” or all of “X”. Inthe context of a conversation, the term “portion” means some or all ofthe conversation.

As used herein, including in the claims, the phrase “using” means “usingat least” and is not exclusive. Thus, e.g., the phrase “using X” means“using at least X.” Unless specifically stated by the use of the word“only”, the phrase “using X” does not mean “using only X.”

In general, as used herein, including in the claims, unless the word“only” is specifically used in a phrase, it should not be read into thatphrase.

As used herein, including in the claims, the phrase “distinct” means “atleast partially distinct.” Unless specifically stated, distinct does notmean fully distinct. Thus, e.g., the phrase, “X is distinct from Y”means that “X is at least partially distinct from Y,” and does not meanthat “X is fully distinct from Y.” Thus, as used herein, including inthe claims, the phrase “X is distinct from Y” means that X differs fromY in at least some way.

It should be appreciated that the words “first” and “second” and so onin the description and claims are used to distinguish or identify andnot to show a serial or numerical limitation. Similarly, the use ofletter or numerical labels (such as “(a)”, “(b)”, and the like) are usedto help distinguish and/or identify, and not to show any serial ornumerical limitation or ordering.

While the invention has been described in connection with what ispresently considered to be the most practical and preferred embodiments,it is to be understood that the invention is not to be limited to thedisclosed embodiments, but on the contrary, is intended to cover variousmodifications and equivalent arrangements included within the spirit andscope of the appended claims.

We claim:
 1. A zipper comprising: a first tape and a second tape; andmultiple interlocking elements connected to each of the first tape andthe second tape, wherein interlocking elements from the first tape mayjoin with interlocking elements of the second tape, and wherein thefirst tape is formed from a first fabric compacted to a first degree ofcompaction, and wherein the second tape is formed from a second fabriccompacted to a second degree of compaction distinct from the firstdegree of compaction, wherein at least a portion of the first tape and acorresponding at least a portion of the second tape are curved.
 2. Thezipper of claim 1, wherein the first fabric and the second fabric areselected from cotton or polyester or nylon.
 3. The zipper of claim 1,wherein the first tape and the second tape were compacted prior to beingconnected to the interlocking elements.
 4. The zipper of claim 1,wherein the interlocking elements comprise teeth or a coil and areformed from brass or steel or stainless steel or nylon.
 5. The zipper ofclaim 1, wherein the first tape comprises a first fusible substrate. 6.The zipper of claim 5, wherein the second tape comprises a secondfusible substrate.
 7. The zipper of claim 1, wherein the interlockingelements were attached to the first tape and the second tape after thefirst fabric and the second fabric were compacted.
 8. The zipper ofclaim 7, wherein the interlocking elements were attached to the firsttape and the second tape after fusible substrate was fused withcompacted fabric.
 9. The zipper of claim 1, wherein a curve of the firsttape was caused, at least in part, by compaction of the first tape. 10.The zipper of claim 9, wherein a curve of the second tape was caused, atleast in part, by compaction of the second tape.
 11. The zipper of claim9, wherein the interlocking elements were attached to the first tapebefore the first tape was curved.
 12. The zipper of claim 11, whereinthe interlocking elements were attached to the second tape before thesecond tape was curved.
 13. The zipper of claim 1, wherein the firsttape was compacted using a compactor.
 14. The zipper of claim 13,wherein the first tape is woven with a first edge portion having atighter weave than the rest of the first tape.
 15. The zipper of claim14, wherein the second tape is woven with a second edge portion having atighter weave than the rest of the second tape.
 16. The zipper of claim14, wherein at least a portion of the first tape is fused with a fusiblesubstrate.
 17. The zipper of claim 14, wherein less than the entirezipper is curved.
 18. The zipper of claim 14, wherein the zipper hasmore than one curve.
 19. The zipper of claim 14, wherein at least aportion of the first tape has a different degree of curvature than acorresponding at least a portion of the second tape.
 20. A productcomprising a zipper according to claim
 1. 21. The product of claim 20,wherein the product is selected from: a garment, footwear, an item ofluggage, an item of sports equipment, boat covers, bags, pencil cases,backpacks, computer/laptop cases, luggage, zip up portfolio case, zip upstorage bins for toys, sleeping bags, tents, children make up/toiletrybags, lunch bags, hats with zipper pockets, toys, toy clothing.
 22. Amethod of making a zipper, the method comprising: compacting a firsttape to form a compacted first tape having a first degree of compaction;compacting a second tape to form a second compacted tape having a seconddegree of compaction; and attaching interlocking elements to thecompacted first tape; and attaching interlocking elements to the secondcompacted tape, wherein the first degree of compaction is distinct fromthe second degree of compaction, wherein at least a portion of the firsttape and a corresponding at least a portion of the second tape arecurved.
 23. The method of claim 22, wherein less than the entire zipperis curved.
 24. The method of claim 22, wherein the zipper has more thanone curve.
 25. The method of claim 22, wherein a curve of the first tapewas caused, at least in part, by compaction of the first tape.
 26. Themethod of claim 25, wherein a curve of the second tape was caused, atleast in part, by compaction of the second tape.
 27. The method of claim22, further comprising: after compaction of the first tape, fusing afirst fusible substrate to the compacted first tape; and/or aftercompaction of the second tape, fusing a second fusible substrate to thesecond compacted tape.
 28. The method of claim 22, wherein the firsttape and the second tape are compacted using a heated drum.
 29. Themethod of claim 22 wherein the first tape is woven with a first edgeportion having a tighter weave than the rest of the first tape.
 30. Themethod of claim 22, wherein the first tape was formed as part of a firstzipper and the second tape was formed as part of a second zipper.
 31. Amethod comprising: making a first zipper, the first zipper comprising afirst tape and a second tape and first interlocking elements attached tothe first tape and the second tape; making a second zipper, the secondzipper comprising a third tape and a fourth tape and second interlockingelements attached to the third tape and the fourth tape; and forming athird zipper from the first tape and some of the first interlockingelements and the third tape and some of the second interlockingelements, wherein at least a portion of the first tape and acorresponding at least a portion of the third tape are curved.
 32. Themethod of claim 31, wherein a curve of the first tape was caused, atleast in part, by compaction of the first tape.
 33. The method of claim32, wherein a curve of the third tape was caused, at least in part, bycompaction of the third tape.
 34. The method of claim 31, wherein lessthan the entire first tape is curved and less than the entire third tapeis curved.
 35. The method of claim 31, wherein the third zipper has morethan one curve.
 36. A product comprising a zipper made according to themethod of claim 22.